Method and apparatus for producing pile fabric



S. ADLER arch 14, 1967 METHOD AND APPARATUS FOR PRODUCING FILE FABRIC Filed Aug. 12, 1963 8 Sheets-Sheet l INVENTOR. 50A (ma/v /404 5/8 S. ADLER 1 arch 14, 1967 METHOD AND APPARATUS FOR PRODUCING FILE FABRIC 8 Sheets-Sheefc 2 Filed Aug. 12, 1963 ATTOE/I EV s. ADLER 3,309,252

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[NV ENTOR 50L aMo/v A204 5/? flaw [224% S. ADLER March 14, 1967 METHOD AND APPARATUS FOR PRODUCING FILE FABRIC Filed Aug. 12, 1963 8 Sheets-Sheet '7 if] II! Mi INVENTOR. $04 o/wa/v flue? METHOD AND APPARATUS FOR PRODUCING FILE FABRIC Filed Aug. 12, 1963 8 Sheets*Sheet 8 INVENTOR. 50L a/ w/v #04 5 United States Patent 3,309,252 METHOD AND AFPARATUS FOR PRGDUClNG FILE FABRIC Soiomon Adier, Kew Gardens, N.Y., assignor to Adler Process Corp, New York, N.Y., a corporation of New York Filed Aug. 12, 1963, der. No. 301,425 12 Claims. (Cl. 156-72) This invention relates to pile fabrics. More particularly, this invention relates to pile fabrics, such as carpeting, rugs and the like, and to a method and apparatus for producing the same.

Various methods and apparatus have been employed for the production of pile fabrics, such as carpeting and rugs. In general, those methods and apparatus employ-' ing a weaving technique are capable of producing quality pile fabrics exhibiting a dense pile and long service or wearing life. Woven pile fabrics, however, are relatively expensive to produce and as a result woven pile fabrics are costly. Pile fabrics and carpeting have also been prepared by non-weaving techniques, such as by knitting and by tufting. The pile fabrics produced by such techniques generally exhibit a relatively loose pile and are less pleasing in appearance but are capable of being produced at a relatively high rate and inexpensively.

The textile industry, particularly that portion thereof involved in the production of pile fabrics, such as carpeting and rugs, has long been interested in a fast, practical, inexpensive method and apparatus for the production of pile fabrics having a relatively dense pile and exhibiting long wearing life and simulating a woven pile fabric. Those techniques employed and suggested heretofore for the manufacture of such pile fabrics have not been entirely satisfactory.

Accordingly, it is an object of this invention to provide a pile fabric, such as a pile fabric suitable for use as carpeting, rugs and the like, which is capable of being produced at a high rate and relatively inexpensively.

It is another object of this invention to provide a pile fabric simulating a woven pile fabric.

It is another object of this invention to provide an improved method and apparatus for the production of pile fabrics, such as carpeting, rugs and the like.

Still another object of this invention is to provide a method and apparatus capable of producing pile fabrics continuously, at a relatively high rate of production and inexpensively.

Yet another object of this invention is to provide a composite pile fabric made up of yarn material comprising the pile and a formed film material comprising the backing for the pile and serving to bind together the pile, the formed film material together with the yarn material making up an integral pile fabric or structure, together with means and apparatus for puroducing the same.

How these and other objects of this invention are accomplished will become apparent in the light of the accompanying disclosure made with reference to the accompanying drawings wherein:

FIG. 1 is a schematic representation of the various steps and equipment for the production of a pile fabric in accordance with this invention;

FIGS. 2 and 3 are schematic cross sectional views of a pile fabric in accordance with this invention;

FIG, 4 is another schematic view illustrating procedores and apparatus for the manufacture of a pile fabric in accordance with a special embodiment of this invention;

FIGS. 5 and 6 are schematic cross sectional views of pile fabrics produced by the method and apparatus illustrated in FIG. 4;

3,3d9,252 Patented Mar. 14, 1967 FIGS. 7a, 7b and comprise in combination a longitudinal view in partial cross section of an apparatus in accordance with this invention for the manufacture of pile fabrics.

FIGS. 8 and 9 schematically illustrate arrangements of apparatus and processing steps in accordance with this invention for the manufacture of pile fabrics;

FIG. 10 is a more detailed fragmentary view in partial cross section of apparatus useful for the manufacture of pile fabrics;

FIG. 11 is a cross sectional view taken along line 1111 of FIG. 10.

FIG. 12 is a fragmentary cross sectional view showing certain operational features of the apparatus of FIG. 10;

FIG. 13 is a view of the apparatus of FIG. 10 taken along line 1313; and wherein FIGS. 14 and 15 illustrate various embodiments of an element useful in the practice of this invention.

In accordance with this invention an improved pile fabric useful as carpeting, rugs and the like comprises an array of pile material bonded to backing material, said backing material making up the binding agent for said pile material. More particularly, a pile fabric in accordance with this invention comprises backing material, U-shaped pile material embedded in said backing material and disposed substantially perpendicularly to said backing material, said U-shaped pile material only being embedded in said backing material at the U-curved portion thereof, said backing material comprising film-forming material applied to and coating said U-curved portion of said pile material.

Referring now to the drawings, particularly FIG. 1 thereof, which schematically illustrates a practice of this invention, warp yarn 10 is fed from Warp beam 11 over guide roll 12 onto an endless belt, generally indicated by reference numeral 14, of loop-forming members 15, such as wires, bars or similar members, disposed in spaced relationship with respect to each other and transversely with respect to warp yarn 10. As warp yarn 10 moves on and over loop-forming members 15, blade 16 is moved into the space between an adjacent pair of loopforming members 15 depressing the warp yarn there'between to form loops 18. Blade 16 is then withdrawn from between loop-forming members 15 and as blade 16 is withdrawn presser foot assembly 19 serves to retain the thus-formed yarn loops 18 between the loop-forming members 15.

As the endless belt or array 14 of loop-forming members 15 carrying with it the formed loops 18 moves in the direction indicated by the arrows, the formed loops are cut by cutting member 20, such as a cutting blade, descending between an adjacent pair of loop-forming members 15 and severing the loops of warp yarn therebetween. The resulting cut loops 18a, now substantially U-shaped and depending from loop-forming members 15 and held therebetween, move along with belt 14 of loopforming members 15 and have applied to the surface thereof an amount of adhesive, film-forming material 21 dispensed from a suitable coating or dispensing device 22. The dispensed, adhesive, film-forming material, such as a vinyl plastisol or latex, coats the U-shaped portion of cut loops 18a. The thus-coated warp yarn passes under the influence of a curing device, generally indicated by reference numeral 24, for effecting the curing of the adhesive, film-forming material applied to the warp yarn. As illustrated the curing device may comprise a band or belt 25 adapted to turn on rollers 25a and evenly distribute the coating material onto the warp yarn and to force the coating material into the interstices thereof. Desirably, the surface of belt 25 in contact with the adhesive coating material may be patterned so as to emboss a suitable pattern onto the film-forming adhesive material during the curing operation. Radiant heaters 25b or the like serve to heat belt 25 to a suitable curing temperature.

After the cured, adhesive, film-forming material and the warp yarn leave the curing operation due to the motion of the endless array or belt 14, the thus-coated warp yarn material is cooled at a cooling station, generally indicated by reference numeral 26 which, desirably, may comprise means, such as a hood 28, for directing a flow of relatively cold air supplied via conduit 29 onto the coated warp yarn material. Upon continued rotation or movement of the endless belt, the thus-formed pile fabric comprising warp yarn embedded in the adhesive filmforming material is removed and passed to a suitable wind-up station.

FIG. 2 illustrates in cross sectional view a pile fabric produced in accordance with the method illustrated in FIG. 1 comprising cut yarn 18a embedded and adhesively joined at its U-shaped portions within a backing made up of cured, adhesive, film-forming material 21a.

FIG. 3 schematically illustrates in cross section another pile fabric produced in accordance with the method illustrated in FIG. 1 and having substantially the same structure, save the pile portion thereof is made up of uncut loops 18.

In the manufacture of a pile fabric illustrated in FIGS. 2 and 3 a sufiicient amount of adhesive, film-forming material should be applied to the looped warp yarn at the U-curved portions thereof so as not only to bind together the looped warp yarn but also to provide an integral, self-supporting structure. The thickness of the adhesive film-forming material may be any suitable thickness effective to impart the desired structural strength and integrity to the finished pile fabric. If desired, a foaming agent may be incorporated in the film-forming material and foamed therein during the curing operation so as to produce a cushiony feel with respect to the pile fabric.

Reference is now made to FIG. 4 of the drawings which represents another embodiment of the practice of this invention and wherein the same reference numerals are employed, as were employed in connection with FIG. 1, to identify the same or equivalent elements. Warp yarn from warp beam 11 is supplied to an endless array or belt 14 of loop-forming members 15 which are disposed and adapted to move in the direction indicated by the arrows. As the warp yarn moves over and onto an adjacent pair of loop-forming members 15, blade 16 descends therebetween and forms loops 18 of warp yarn between the adjacent pair of loop-forming members. Presser foot 19 serves to retain loops 18 in position between loop-forming members 15 as blade 16 is withdrawn.

As the thus-formed loops 18 of warp yarn move along with belt 14 of loop-forming members 15 cutting blade 20 descends and cuts each loop of Warp yarn as it moves directly beneath blade 20. Thereupon the surfaces of the cut loops 18a have applied thereto or have coated thereon an amount of adhesive film-forming material 21 dispensed from coating device 22.

The thus-coated cut loops 18a have applied thereto burlap backing 24 supplied from roll 25. The burlap backing is joined to the coating of adhesive film-forming material 21 as the burlap backing passes under guide roll 17. An additional layer or coating of adhesive filmforming material 21 is then applied to the burlap backing material 24. Thereupon, a second layer of burlap backing material 23 from roll 27 is applied as it passes under guide roll 36. The resulting composite comprising cut warp yarn material with the two layers of burlap backing material, together with the film-forming adhesive, passes through curing and/or drying station 31 provided with radiant heaters 32 or equivalent heating device so as to cure and/ or dry the adhesive and bind the burlap backing material to the cut warp yarn to form an integral composite structure. Thereupon, the cured and/or dried composite pile fabric structure passes to cooling station 26 wherein it is cooled by a flow of relatively cold air supplied to hood 28 via conduit 29. The resulting substantially finished pile fabric is then separated from the endless array of loop forming members and passed to a suitable wind-up roll.

FIG. 5 illustrates the resulting composite pile fabric structure made up of two layers of burlap backing 23 and 24 bonded to cut yarn loops 18a by means of a cured, adhesive, film-forming material 21a. FIG. 6 schematically illustrates substantially the same composite pile fabric structure as is illustrated in FIG. 5 save the pile loops 18 are uncut.

In the pile fabric embodiments of this invention illustrated in FIGS. 5 and 6 greater latitude is available in the choice and the amount of binding agent since the important function of the binding agent therein is to adhere the looped Warp yarn together and to the backing and is not required to serve as the backing material per se. Structural integrity is imparted to the composite pile fabric by the burlap backing material in cooperation with the adhesive material joining the burlap backing to itself and to the looped warp yarn material.

Various materials well known in the trade may be employed as the warp yarn material. Suitable such materials include cotton, Wool and the various other natural fibers of animal and/ or vegetable origin and mixtures or blends thereof, as well as the numerous synthetic fibers including nylon, dacron, .orlon and blends and mixtures thereof, also fibers or yarns made from the various polyolefinic materials, such as polyethylene and polypropylene. Further, the backing material may comprise any suitable material compatible with the warp yarn material and/or the adhesive agent employed. Suitable backing material includes burlap, canvas, scrim, paper, plastic sheet material, such as polyvinyl chloride, polyethylene and the like. Further, the adhesive bonding agent, as indicated hereinabove, is desirably film-forming. Suitable such film-forming materials obtainable in plastisol or latex form include polyvinyl chloride, polyvinyl acetate and natural and synthetic rubber and the like.

Referring now to FIGS. 7a, 7b and 7c, which illustrate one embodiment of the apparatus in accordance with this invention for the manufacture of the pile fabric schematically illustrated in FIG. 4, warp yarn from warp beam 51 driven by suitable means comprising motor 52 and drive belt 54, is intermittently supplied over guide rolls 55 through adjustable comb or reed assembly 56. Handle 58 operatively connected to comb 56 serves to adjust (increasing or decreasing) the distance between the warp yarn depending upon the pile density desired in the finished pile fabric. Additionally, comb 56 serves to keep the warp yarns in parallel relationship. The warp beam drive mechanism is adapted to provide gradual'acceleration and deceleration of Warp beam 51 so as to provide a desired amount of slack in the warp yarn before being drawn through comb assembly 56.

Warp yarn 50, after passing through comb assembly 56, passes under guide roll 59 onto loop-forming members 60. Loop-forming members 60, such as suitably shaped bars or rods, are fixed to links 61 which make up an endless conveyor belt and which is engaged and driven by gear 62. Gear 62, in turn, is intermittently driven by motor 64 via drive chain 65. Like the drive mechanism for warp beam 51 drive mechanism or motor 64 is adapted to provide gradual or uniform acceleration or deceleration. Desirably, drive mechanism 64 advances the array of links 61 in incremental amounts for a short distance, such as about 1 inch, more or less, at a high rate, such as at a rate of about 2 to 6 incremental advances or movements per second.

As warp yarn 5B advances over a pair of adjacent loop forming members and becomes positioned beneath blade 66, blade 66 is moved downwardly by piston 68 operative within cylinder 69 to depress warp yarn 50 between loop-forming elements 60 to form a loop therebetween. Each downward movement of loop-forming blade 66 forms warp yarn loops between loop-forming members 60. As blade 66 is withdrawn the array of links 61 and loop-forming members 60 advance a suitable distance so as to permit blade 66 on its next descending stroke to enter the next, adjacent pair of loop-forming members 60 to form additional warp yarn loops therebetween. Adjustable, resiliently-mounted presser foot assembly 69 serves to retain the warp yarn loops in position between the loop-forming members 60.

Upon continued movement of the array of loop-forming members beneath loop-cutting station, generally indicated by reference numeral 70, cutting blade 71 descends to intermittently cut the warp yarn loops. Desirably, cutting blade 70 is operated in synchronism with loop-forming blade 66 and is similarly operated by piston 72, operative within cylinder 74. Photoelectric cell sensors 75 in cooperation with light sources 76 assure that loop-forming blade 66 and cutting blade 71 descend between the spaces between adjacent pairs of loop-forming members 60. The resulting cut warp yarn loops pass under loopretaining belt 78 which is mounted on the machine frame 53 and adjustable to provide desired pressure onto the loops via belt 78 to maintain the Loops in position between loop-forming members 60.

Thereupon, the cut yarn loops pass to an adhesive applying station wherein a liquid adhesive material is supplied via conduit 79 and nozzle 80 onto the top of the warp yarn loops, spreaders 81 and 82 serving to uniform ly coat the adhesive material onto the warp yarn.

The adhesive coated warp yarn has deposited thereon a layer of burlap backing 84 supplied from a suitable source, not shown. Burlap backing 84 is applied to the adhesive coated yarn material as it passes under guide roll 85. An additional amount of adhesive material is then applied to the burlapbacking as previously described and a second layer 86 of burlap backing from a suitable source, not shown, is applied to the first deposited layer of burlap backing as the second layer 86 moves under guide roll 88.

Thereupon, the resulting composite pile fabric structure passes through a drying station, generally indicated by reference numeral 89, comprising hood 90 provided with radiant heating means 91, such as infrared ray lamps. While passing through curing and/or drying station 89 the adhesive material and the composite pile fabric are cured and/or dried. Upon leaving the curing and/or drying station 89 the composite pile fabric passes through cooling station, generally indicated by reference numeral 92. Cooling station 92 comprises hood 93 supplied via conduit 94 with a supply of relatively cool air directed to impinge upon the composite pile fabric as it moves beneath hood 93.

On leaving cooling station 92 the substantially finished composite pile fabric 77 is separated from the loopforming members 60 and passes under guide roll 94 and in contact with and over guide roll 95 to wind-up roll 96 which, desirably, is driven in synchronism with warp beam 51 via drive mechanism or motor 97 through drive belt 98. Wind-up roll 96 is mounted on carriage 99 provided with means for maintaining constant tension on the finished pile fabric. As indicated the wind-up assembly is mounted on transverse rollers 160.

In the loop-forming operation blade 66 is disposed substantially perpendicularly and transversely with respect to warp yarn 50 and loop-forming members 66. In operation loop-forming blade 66 descends at a rate from about 3 to 8 strokes per second. On each downward stroke between loop-forming member 60 blade 66 presses the warp yarn into the available space between loop-forming members 60 to form loops therebetween. Blade 66 then is moved upwardly out of the space and the array of loop-forming members moves a distance to position the next adjacent pair of loop-forming members beneath blade 66. Desirably, so as to facilitate the entry of the blade between loop-forming members 60 and the formation of loops therebetween, means are provided in association with the blade for moving apart the loop-forming members to a slight extent just before blade 66 enters therebetween.

Further, presser foot assembly 69 and retention belt 78 are disposed substantially completely across the array of loop-forming members so as to assure the retention of the loops between the loop-forming members during movement of the array of the loop-forming members.

Loop-forming blade 66 and cutting blade 70 may be a straight edge blade or similarly contoured blades, if desired, to impart a sculptured or contoured effect to the cut loops. If desired, the loops of warp yarn may remain uncut during the manufacture of the pile fabric and subsequently be cut in a separate shearing or cutting operation.

Referring'now to FIG. 8 of the drawings, there is illustrated therein a circular track arrangement for the production of pile fabric in accordance with this invention. As schematically illustrated therein, at loop-forming station, generally indicated by reference numeral 113, warp yarn from Warp beam 111 is supplied over roller 112 through comb 114 and under guide roller 115 to loop-forming station comprising cutter assembly 117, loop-forming blade 118, presser foot 119, cutting blade and retaining belt 121. The aforesaid loopforming operations are carried out so as to produce on carriage 120 an array of looped warp yarn material.

Carriage 120 then moves to adhesive applying station 123 and the surface of the looped warp yarn material is coated with a suitable adhesive material. Thereupon layer 122 of burlap backing is applied before going to a second adhesive applying station 124 wherein a second coat of adhesive is applied. Thereupon a second layer 125 of burlap backing is applied and the resulting assembly passes through a drying and cooling tunnel 126. Upon leaving drying and cooling tunnel 126 the resulting finished pile material 128 is removed onto wind-up roll 129 and carriage 120 is then available for the formation of additional loops of warp yarn material thereon. As illustrated in the drawing, the arrangement of FIG. 8 is suitable for the manufacture of pile fabric in fixed lengths and widths depending upon the length and width of the carriages. Moreover, the aforesaid operations can be carried out on a substantially continuous basis for the substantially continuous production of pile fabric.

Instead of a circular track arrangement, such as illustrated in FIG. 8, carriage 120 may be adapted and disposed to move in a straight line path. FIG. 9 illustrates this embodiment of the practice of the invention wherein the various operations in the manufacture of a pile fabric in accordance with this invention are indicated and their relationship to each other.

Referring now to FIGS. 10-13 of the drawings, there is illustrated therein in greater detail a particular embodiment of apparatus in accordance with this invention for the manufacture of pile fabric. Carriage mounted on flanged wheels 151 adapted to move along rails 152 is intermittently moved beneath loop-forming blade 154 which is connected to bar 155. Bar 155, in turn, is connected to lever 156 which is adapted for up and down movement so as to move blade 154 in an up and down direction, the up and down movement of blade 154 being guided by pins 158 disposed within slots 159 provided on each side of blade 154.

As blade 154 is moved up and down so as to enter the space between loop-forming members 160 through suitable linkage indicated by reference numeral 161 and comprising levers 161a, 161b, 1610 and 161d and ratchet 162, loop-forming members 160 are intermittently advanced so that upon the next descending stroke blade 154- enters the space between the next successive loop- .material from a warp forming members, said loop-forming members being disposed transversely forming membeis. pn tiatihn of 19121653154 between the loop-forming members 160 is aided by hedging blade 164 disposed on either side of blade 154.

In operation wedging blade 164 forces apart collar spacers 165 fixed to each end of loop-forming members 160 and increases the available space between loop-forming members 160 for the penetration of blade 154 therebetween. Collar spacers 165 are useful to provide space between the loop-forming members 160 for the loops of warp ya'rn and ai'e iiiaintaiiicd, in direct contact with eaclipther by meansof pusher spring 168. ibspderining members are accordingly resiliently ariayetd s8 tliit wedging blade 164 moves bfetwe en a pair of adjacent collar spacers 165 the collar spacers and lobp-fbrn'iing members are urged against spring 168.

Presser foot 169 is provided adjacent blade 154 to retain the loops in position between'the loop-forming members, see particularly FIG. 12. If desired, knife blade 170 actuated in synchronism with blade 154 is provided to cut the loops thus formed between the loopforming members 160, cutting being effected as the knife descends between a pair of loop-forming members and bears against the upper surface of member 171.

As illustrated, see articularly FIGS. 11 and 13, loopforming members 16! made up of an upper rod, such as a rod having a circular cross section, joined by connecting bars 172 to lower rod or bar 174, preferably of smaller cross section than the up er rod. The loop-forming members desirably are su ported by and/or contact the upper surface of floorime'mber' 171,

v Piss. 14 and i illustrate profiles of various loop fbiiiiing blades useful for achieving a sculptured efiect on pnaraenes prepares iii accordance with this inven= ticiri; T he reap-raining blade assmbly of l4 partsan undulating suffatic it? the pile teens and the loopdbrming blade of FIG. 15 imparts a more sharply defined ridge effect. I I A As will be apparent to those skilled in the art in the light ofthe foregoing disclosure, many modifications, substitutions and alterations afe possible in the practice of this invention without departing from the spirit or scope thereof.

I claim:

1. A method for producing a pile fabric, such as carpeting, rugs and the like, which comprises disposing yarns over loop-forming members, said loop-forming members being disposed transversely with respect to said yarns and spaced from each other, depressing said yarns between said loop-forming members to form loops of yarn therebetween while maintaining said loops of rial between said loop forming members by pressing said Warp material onto and against the top of said loopforming members, cutting said loops of yarn formed between said loop-forming members at the bottom of the loop portion thereof which is depressed between said loop-forming members while maintaining said loops of yarn in position between said loop-forming members, applying adhesive material onto the yarn portions supported on said loop-forming members, said yarn portions making up the bases of the thus-formed and cut loops :and applying backing material to the adhesive coated yarn portions to bind the thus-formed and cut loops to said backing material.

2. A method for producing a pile fabric, such as carpetfing, rugs and the like, which comprises advancing warp beam over and in contact with loopwith respect to said warp material and .spaced from each other, interrupting the advancement of said warp material and depressing said warp material between an adjacent pair of said loop-forming members to form loops of warp material therebetween, additionally advancing and depressing said warp material in substantially the aforesaid sequence of operations to continuously form an array of loops between each successive warp matepair of loop-forming members while maintaining said loops of warp material between said loop-forming mem by pressing said warp material onto and against the top of sai it??? forrriirrg members, applying adhesive material'onto the warp material portions supported on. said loop-forming members, said Warpriiaterial portionsmaking up the bases of the thus-formed loops and apply ing backing material to the adhesive coated warp mate-- rial portions to bind the thus-formed loops of said back ing material.

3. A method in accordance with claim 2 wherein as said war material is depressed between an adjacent pair of lot iporriti-rig members to form loops of warp material tlifer'btwri and the thus-formed loops are cut.

4, A- instead accordance with claim 2 wherein as said warp material is depressed between an adjacent pair of loop-forming riimbfs form loops of warp material therebetween, other, pfviously formed loops of warp material are cut. V

5. Apparatus useful for producing a pile fabric, such: as carpeting, rugs and the like, comprising an array of spaced parallel-aligned, loop-forming members, said loop forming members being disposed in substantially side-byside coplanar relationship, means for advancing warp material over and in contact with said array of loopforming members, means for depressing said warp mate rial between a pair of adjacent loop-forming members, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop-forming members, means for cutting said warp material at the bottom of the loop portion thereof which is depressed between said loop-forming members and means for applying adhesive film-forming material to the surfaces of said warp material on said loop-forming members.

6. Apparatus for producing pile fabric, such as carpetinggrugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loop-forming members bein disposed in substantially side-by-side coplanar relationship, means for advancing warp material over and in contact with said array of loop-forming members, means for interrupting the advancement of said warp material over said loop-forming members, means for depressing said warp material between a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop-forming members and means for applying adhesive film-forming material to the surfaces of said warp material on said loop-forming members.

7. Apparatus for producing a pile fabric, such as carpeting, rugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loop-forming members being disposed in substantially side-by-side coplanar relationship, means for advancing warp material over and in contact with said array of loop-forming members, means for interrupting the advancement of said warp material over said loop-forming members, means for depressing said warp material between a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop-forming members and means for applying adhesive film-forming material to the surfaces of said warp material on said loop-forming members.

8. Apparatus :for producing a pile fabric, such as carpeting, rugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loop-forming members being disposed in substantially side-by-side coplanar relationship, means for advancing warp material over and in contact with said array of loop-forming members, means for interrupting the advancement of said warp material over said loop-forming members,

means for depressing said warp material between -a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said Warp material between said loop-forming members, means for cutting said warp material at about the middle of that portion depressed between said loop-forming members and means for applying adhesive film-forming material to the surfaces of said warp material on said loop-forming members to provide a backing for said warp material.

9. Apparatus useful for producing a pile fabric, such as carpeting, rugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loopforming members being disposed in substantially sidebyside coplanar relationship, means for advancing warp material over and in contact with said array of loopforming members, means for interrupting the advancement of said warp material over said loop-forming members, means for depressing said warp material between a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop forming members and means for cutting said warp material at that portion thereof depressed between said loop-forming members.

10. Apparatus useful for producing a pile fabric, such as carpeting, rugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loop-forming members being disposed in substantially side-by-side coplanar relationship, means for advancing warp material over and in contact with said array of loop-forming members, means for interrupting the advancement of said warp material over said loop-forming members, means for depressing said warp material between a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop-forming members, means for cutting said warp material at that portion thereof depressed between said loop-forming members and means for applying adhesive film-forming material to the surfaces of said warp material on said loop-forming members.

11. Apparatus useful for producing a pile fabric, such as carpeting, rugs and the like, comprising an array of spaced, parallel-aligned, loop-forming members, said loop-forming members being disposed in substantially side-by-side coplanar relationship, means for advancing warp material over and in contact with said array of loop-forming members, means for interrupting the advancement of said warp material over said loop-forming members, means for depressing said warp material between a pair of adjacent loop-forming members as the advancement of said warp material thereover is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said loop-forming members, means for cutting said warp material at that portion thereof depressed between said loop-forming members, means for applying adhesive material agent to the exposed surfaces of said warp material on said loop-forming members and means for applying backing material to the thusadhesive coated surfaces of said warp material.

1.2. Apparatus useful for producing a pile fabric, such as carpeting, rugs and the like, comprising a closed, endless array of spaced, parallel-aligned, loop-forming members, said loop-forming members being disposed in substantially side-by-side coplanar relationship, means for interruptingly advancing said array of loop-forming members a distance equal to the distance separating the mid-points of an adjacent pair of loop-forming members, means for feeding warp material over and in contact with said array of loop-forming members as said array is interruptingly advanced, means for depressing said warp material between a pair of adjacent loop-forming members as the movement of said array of loop-forming members is interrupted, means for pressing said warp material onto and against the top of said loop-forming members to retain said warp material between said l0op-' forming members, means for applying adhesive material to the exposed surfaces of said warp material on said loop-forming members and means for applying backing material to the thus-coated surfaces of said warp material.

References Cited by the Examiner UNITED STATES PATENTS 1,822,510 9/1931 Smith 156-435 2,116,048 5/1938 Smith 156-435 X 2,638,427 5/1953 Roberts 156-72 X 2,675,337 4/1954 Walker et al. 156-72 3,052,947 9/1962 Feild 161-63 X 3,142,611 7/1964 Mills 156-72 X 3,206,343 9/1965 McFarlane 156-72 EARL M. BERGERT, Primary Examiner. HAROLD ANSHER, Examiner. 

1. A METHOD FOR PRODUCING A PILE FABRIC, SUCH AS CARPETING, RUGS AND THE LIKE, WHICH COMPRISES DISPOSING YARNS OVER LOOP-FORMING MEMBERS, SAID LOOP-FORMING MEMBERS BEING DISPOSED TRANSVERSELY WITH RESPECT TO SAID YARNS AND SPACED FROM EACH OTHER, DEPRESSING SAID YARNS BETWEEN SAID LOOP-FORMING MEMBERS TO FORM LOOPS OF YARN THEREBETWEEN WHILE MAINTAINING SAID LOOPS OF WRAP MATERIAL BETWEEN SAID LOOP-FORMING MEMBERS BY PRESSING SAID WARP MATERIAL ONTO AND AGAINST THE TOP OF SAID LOOPFORMING MEMBERS, CUTTING SAID LOOPS OF YARN FORMED BETWEEN SAID LOOP-FORMING MEMBERS AT THE BOTTOM OF THE LOOP PORTION THEREOF WHICH IS DEPRESSED BETWEEN SAID LOOP-FORMING MEMBERS WHILE MAINTAINING SAID LOOPS OF YARN IN POSITION BETWEEN SAID LOOP-FORMING MEMBERS, APPLYING ADHESIVE MATERIAL ONTO THE YARN PORTIONS SUPPORTED ON SAID LOOP-FORMING MEMBERS, SAID YARN PORTIONS MAKING UP THE BASES OF THE THUS-FORMED AND CUT LOOPS AND APPLYING BACKING MATERIAL TO THE ADHESIVE COATED YARN PORTIONS TO BIND THE THUS-FORMED AND CUT LOOPS TO SAID BACKING MATERIAL. 